Get active production moving faster with optimized setup processes
→ Greater productivity: What potential lies untapped in your manufacturing?
→ Lean at the machine: Turning setup processes into productive time
→ How does virtual setup work in the programming process?
→ Automatic setup documentation for the shop
→ Extensive benefits from virtual setup
Machine idle time costs real money. On average, a manufacturing company spends roughly 600 hours on setup processes per machine every year*. But setup processes are absolutely essential, even if they’re not directly associated with value creation. Reducing setup time therefore plays a critical role in an efficient, flexible and smooth-running manufacturing operation. This blog article and our PDF "Less setup, more manufacturing" explain more about setup optimization, provide specific optimization tips and highlight your potential savings.
*Based on records and empirical data from Tebis Consulting's comprehensive benchmark database.
Transforming setup processes: Lean at the machine
If you want to optimize your setup processes, you need precise knowledge of all the individual steps. A traditional setup process in production usually involves setup preparation, clamping, checking the setup situation and setup removal.
For lean manufacturing, setup processes are divided into internal and external tasks. The goal of this division is to perform certain setup activities in parallel with productive time to whenever extent possible.
Internal setup activities can only be performed while the machine is idle: Workpiece setup and adjustment, tool change and calibration must be completed as quickly as possible.
Use virtual setup for better 24/7 manufacturing
Yet another setup scenario is gaining traction: virtual setup. This is performed upstream of shop operations offline on the PC ,and it can be done in parallel with other manufacturing orders. Advances in digitalization and networking are putting more and more focus on IT-supported processes in machining companies. Because the virtual approach to setup optimization offers even more automated benefits that can keep your machinery in 24/7 productive operation whenever possible.
Reduce idle time by shifting operations away from the machine
In a modern manufacturing company, you can move some processes all the way to the programming office. Moving setup definition to the CAD/CAM programming process may sound unusual at first, but it prevents unnecessary delays in production. All without significantly increasing the programming effort. Because in virtual set-up, the setups are defined quickly and reliably and are checked and documented in the CAD/CAM system.
Virtual setup is performed in your virtual CAD/CAM workspace. It doesn't matter whether it’s done in design, in work preparation or by a CAM programmer. Here’s the important part: The user can also automatically define the setup situation in a convenient software dialog. This IT support allows you to precisely plan the setup process and machining right from the start. The setups are optimally prepared, including the following:
- Machine/machine head
- Machining tools
- Clamping devices, shuttle tables and units
- Clamping and tilt directions
- Reference points, zero point and parameters
Achieve your goals more easily in the CAD/CAM software dialog
The reason virtual setup works so precisely is that the CAD/CAM software uses digital twins of your machine, clamping devices and tools. The true-to-life parameters of your manufacturing environment are stored in the software and are linked associatively. In virtual setup, the user is provided with recommendations in dropdown menus: for example, the appropriate clamping devices for the selected machine.
Setup planning in the Tebis CAD/CAM software is fast and safe. New users, trainees or substitutes can also learn how to perform setup and CAM programming risk-free in the virtual environment.
Virtual setup using a clamping device library also ensures transparency in the production environment. The machine setup operator no longer has to worry about the setup, clamping devices or appropriate tools. Instead, they receive digital setup documentation and figures, along with a fully collision-tested and verified NC program. Everything always goes to the right machine with no loss of information. A viewer shows the associated 3D model. The machine operator can immediately start preparing the external setup. There are no more requests for additional information, no unnecessary teardowns and significantly less machine idle time.
Your benefits from "setup during programming":
- Increases the productive time of your machines
- At least halves the time needed for internal setup
- Little to no extra time required for CAM programmers
- Optimizes setup planning
- Collision-tested setups and verified NC programs
- Clear and complete documentation with no requests for more information
- The NC program takes over integration in the manufacturing process
- Simple task assignment using assistants in the office or shop
- More unattended machine runtime at night and over weekends
Less setup, more manufacturing!
Get active production moving faster with virtual setup in parallel with productive operating time
Just like you, your machines work best without interruptions. Do them this favor:
Optimize your setup processes and setup time. With virtual setup, you can prepare many steps in parallel with runtime. Let's highlight the benefits and give you some tips.
